Apparatus for preparing melon juice concentrate

ABSTRACT

An apparatus for preparing a melon juice concentrate, such as watermelon juice concentrate, includes a finisher with brushes for separating melon flesh from melon rind including leaving at least 1/16 inch flesh on the rind and screens for separating juice from flesh. The apparatus also includes a steamer to reduce bacteria count on whole melon, a chopper for chopping melons into pieces less than about 16 inches square, an extractor for extracting juice from the flesh, and an evaporator for concentrating melon juice to form melon juice concentrate. The steamer includes a cylinder frame, steam jets directing steam through apertures in the cylinder frame at whole melon therein, and a motivator to move the whole melon along the cylinder frame. The apparatus can also process cantaloupe, honeydew melon, and other melon.

This application claims benefit of provisional application Ser. No.60/712,985, filed Aug. 31, 2005, entitled WATERMELON EXTRACTS ANDPROCESS OF PRODUCING THE WATERMELON EXTRACTS, the entire contents ofwhich are incorporated herein by reference in its entirety. Thisapplication is related to the following co-assigned, co-inventedapplications filed on even date herewith: Ser. No. 11/469,168, entitledAPPARATUS FOR SEPARATING MELON FLESH FROM RIND; Ser. No. 11/469,192,entitled WATERMELON JUICE PRODUCTS AND FOOD PRODUCTS PRODUCED WITH THEJUICE PRODUCTS; and Ser. No. 11/469,220, entitled PROCESS FOR PREPARINGA MELON EXTRACT AND CONCENTRATE AND PRODUCT PRODUCED BY THE PROCESS.

BACKGROUND OF THE INVENTION

The present invention relates to an apparatus for producing melon juiceand/or juice concentrate.

Natural watermelon extract, including watermelon juice and watermelonjuice concentrate, should ideally have a strong watermelon flavoridentity and a red color. Unfortunately, to date, previously producedwatermelon extract exhibited an “off” flavor primarily as a result of afishy odor and flavor. It is presently believed that previously producedjuices have been produced using the entire watermelon, including therind, and typically have an amber or yellow color.

Some currently available watermelon juice products include additives,such as colorants, sugars, and flavors to mask the fishy taste and odor.Some watermelon juice products also include thickening agents. One suchthickening agent is carrageenan, a phycocolloid derived from seaweed.

The red flesh portion of the watermelon is the portion consumerstypically eat. Therefore, watermelon juice is preferably red in color.The red color desired in watermelon juice can be both observed andquantified. Cloudy watermelon juice can be measured using an instrumentcalled a HUNTER™ colorimeter. The HUNTER™ colorimeter designates colormeasurements into three categories, L, A and B, and assigns a value toeach. The L value measures the “brightness” of the juice, the A valuemeasures the “redness,” and the B value measures the “brown” of a juice.Using these values, different cloudy watermelon juices can be comparedand contrasted on a quantitative basis, providing real numbers in thecomparison.

There are generally two types of watermelon juice, cloudy and clarified.A cloudy fruit juice is generally unfiltered with the cloudiness comingfrom natural fruit material. In the case of watermelon juice, thecloudiness is primarily due to small pieces of flesh remaining in thecloudy juice. Clarified or clear juice is generally derived from cloudyjuice. A HUNTER™ colorimeter is not typically used to quantify color inclarified watermelon juice. Instead, color of a clarified juice extractis typically expressed at percent transmittance at a particular lightwavelength.

There is a significant need for a high-quality manufacturable, naturalwatermelon extract, such as a juice or a concentrate, having a red colorand a strong watermelon flavor identity. There is also a need for anapparatus and a method of producing such an extract. More broadly, thereis a significant need for melon extract, such as a juice or concentratefrom watermelon, cantaloupe, honeydew melon, or similar fruit with rind.

SUMMARY OF THE INVENTION

In one aspect of the present invention, an apparatus for processingwhole melon includes a steam cylinder assembly including a cylinderframe shaped to hold whole melon, steam jets directing steam throughapertures in the cylinder frame at the whole melon, and a motivator tomove the whole melon along the cylinder frame.

In another aspect of the present invention, an apparatus for preparing amelon juice concentrate, such as watermelon juice concentrate includes asteamer to reduce bacteria count on whole melon, a chopper for choppingmelons into pieces less than about 16 inches by 16 inches square, aseparator finisher for separating melon flesh from melon rind includingleaving at least 1/16 inch flesh on the rind, an extractor forextracting juice from the flesh, and an evaporator for concentratingmelon juice to form melon juice concentrate.

These and other features, advantages, and objects of the presentinvention will be further understood and appreciated by those skilled inthe art by reference to the following specification, claims, andappended drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated in, and constitute apart of, the specification illustrate several embodiments of theinvention and together with the description, serve to explain theobjects, advantages, and principles of the invention.

FIG. 1 is a flow diagram illustrating a process of producing a cloudywatermelon concentrate in accordance with the present invention;

FIG. 2 is a perspective view of a steamer of the present invention usedin the process of the present invention;

FIG. 2A is a cross-sectional view of the steamer of the presentinvention showing an outer cylinder, auger, and steam pipes inside thesteamer of FIG. 2 at different levels;

FIG. 2B is an expanded view of the steam pipes of the steamer of FIG.2A;

FIG. 2C is an expanded view of an outer cylinder as shown in the steamerof FIG. 2A;

FIG. 2D is an expanded view of the reverse auger of a steamer of FIG.2A;

FIG. 2E is a side elevational view of a steamer of the presentinvention;

FIG. 3 is an elevated perspective view of a chopping apparatus of thepresent invention;

FIG. 4 is a perspective view of a first finisher of the presentinvention;

FIG. 5 is a cross-sectional view of the first finisher of the presentinvention;

FIG. 6 is an expanded view of the inside of the first finisher of thepresent invention showing brushes, an inside screen, and rotating arms;

FIG. 6A is an expanded view of the brushes, inside screen, and rotatingarm of a first finisher of the present invention, as shown in FIG. 6;

FIG. 6B is an elevational view of a second finisher of the presentinvention;

FIG. 6C is an elevational view of a filter of the present invention;

FIG. 7 is a plan view of the process of a preferred embodiment of thepresent invention; and

FIG. 8 is a flow diagram illustrating a process of producing clarifiedwatermelon concentrate in accordance with the present invention.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENT

FIG. 1 generally shows a process for producing a cloudy watermelon juiceextract, in particular a concentrate, in accordance with the presentinvention. The process generally includes steaming whole watermelonsthat are introduced into a steamer 10 where steam is applied to theexterior surface of the whole watermelons. Next, the steamed wholewatermelons are typically transferred to a chopper 40. The chopperserves to reduce the size of the watermelon pieces. These watermelonpieces typically comprise pieces of watermelon flesh only, pieces ofwatermelon rind only, and pieces of watermelon flesh attached towatermelon rind. At this point in the process, the watermelon fleshincludes watermelon juice. The watermelon pieces are sent to a receivingtank 50. From the receiving tank, the watermelon pieces go to a firstfinisher 60, where the watermelon flesh is substantially separated fromthe watermelon rind. In the first finisher 60, an at least portion ofwatermelon juice is extracted from the watermelon flesh to form amixture. The substantially separated watermelon flesh and juice mixtureis transferred to a second finisher 100. The watermelon rind goes to thewaste auger 150, where it is removed and sent for disposal 160. Thesecond finisher 100 generally substantially removes any watermelon seedspresent in the mixture of watermelon flesh and juice. Once the seeds areremoved, the mixture of watermelon flesh and juice is sent to a filterdevice 110, where the watermelon juice is substantially separated fromthe watermelon flesh. The watermelon juice is transferred to holdingtanks 120 and 130 where edible acid is typically added to adjust the pHof the juice. Once the desired pH level is achieved, the watermelonjuice is optionally sent to an evaporator 140, where water, typicallysubstantially all of the water, is removed to form a watermelonconcentrate. The watermelon concentrate is packaged 170 and sent out asfinished product.

FIG. 2 shows the steamer 10 of the present invention. The steamertypically includes a plurality of vertical supports 12 and cross supportmembers 14, which support the housing 16 of the steam cylinder assembly18. The housing 16 has removable access doors 20, which are primarilyshown as cut away portions in FIG. 2. The support members 12, 14,housing 16, and access doors 20 are typically manufactured from steel.The steamer 10 typically further includes steam supply lines 22, whichfeed the steam lines 24 typically disposed in a parallel manner in thebottom quarter of the housing 16 and spaced below the steamer cylinderassembly 18 with the steam jets 26 directed substantially upward. Thesteam lines 24 and jets 26 could be positioned anywhere in the housing16 so long as steam is applied to the watermelons traversing the steamcylinder assembly 18.

The steam cylinder assembly 18 is typically mounted within the housing16 and includes a main cylinder frame 28 that typically is mounted abovethe steam lines on roller supports 29, which rotate and are mounted onthe inside surface of the housing 16. The steam cylinder assembly 18 isoperably connected, typically by a drive belt assembly, to a motor 30,which provides the drive force necessary to rotate the steam cylinderassembly 18. The belt is typically frictionally engaged to the outsidesurface of main cylinder frame 28. The main cylinder frame 28 typicallyhas a plurality of apertures 27 (FIG. 2A). The apertures 27 as shown inFIG. 2C are typically arranged around the circumference of the cylinderand form parallel rings which extend down the length of the cylinder.Typically, the apertures 27 are from about 2 inches to about 8 incheswide and from about 4 inches to about 14 inches long. More typically,the apertures are from about 2½ inches to about 6 inches wide and fromabout 8 inches to about 12 inches long. Most typically, the aperturesare about 3⅛ inches wide and about 11 inches long. The parallel rings ofthe apertures are typically spaced from about 1 inch to about 12 inchesapart, more typically from about 7 inches to about 11 inches apart, andmost typically about 8⅞ inches apart. While the arrangement of theapertures 27 in the main cylinder frame 28 of the steamer 10 describedis that of a preferred embodiment, those skilled in the art willrecognize that other arrangements will also work in the steamer of thepresent invention. The preferred dimensions of the apertures preventwatermelon fragments that may break off in the steamer from fallingthrough the apertures. The apertures 27 further function to provideaccess points for the steam from the steam lines to contact the exteriorsurface of the watermelon traversing the main cylinder frame.

Typically, the main cylinder frame 28 has a length of from about 18 feetto about 19 feet, and most typically has a length of 18.5 feet. The maincylinder frame 28 typically has a diameter of from about 24 inches toabout 36 inches, more typically from about 30 inches to about 34 inches,and most typically a diameter of about 32 inches.

As shown in FIGS. 2A, 2D, and 2E, inside the main cylinder frame 28includes a reverse auger 31. In operation, the whole watermelons areintroduced into one end of the cylinder assembly 18 of the steamer 10and are conveyed down the length of the cylinder by the auger 31 to theopposite end. Steam is introduced through the steam head on steam jets26 at a typical temperature of from about 212° F. to about 338° F., moretypically from about 220° F. to about 320° F., and most typically fromabout 260° F. to about 310° F. The whole watermelons are typically heldinside the steamer from about 30 seconds to about 90 seconds, moretypically from about 45 seconds to about 70 seconds, and most typicallyfrom about 55 seconds to about 60 seconds. As the whole watermelontravels through the steamer 10, the outside surface of the watermelon issoftened and disinfected. The steaming of the outside surface removesmicrobials that otherwise may cause the watermelon extract to contain anunacceptable total plate count (TPC) of bacteria. It is presentlybelieved that the fact that watermelon grows on the ground as opposed toin, for example, a tree, at least partially causes the increasedtendency for higher bacteria levels in watermelon extract when theexterior of the melons are not steamed or otherwise cleansed prior tobeing subject to further processing in the extracting process.

After leaving the steamer 10, the whole watermelons are conveyed to achopper 40. In operation, a motor 42 drives a cylindrical drum 44 with aplurality of teeth 46 mounted on the exterior portion of the cylindricaldrum 44. A hopper 48 receives the whole watermelons and, through theirweight and the teeth on the drum, the whole watermelons are reduced insize. The chopper 40 exerts pressure on the whole watermelon,essentially “crunching” it into pieces. The watermelon pieces formed bythe chopper 40 typically include pieces of watermelon flesh only, piecesof watermelon rind only, and pieces of watermelon flesh and rindcombined, as well as watermelon juice. Typically, the watermelon piecesare chopped into pieces smaller than about 16 inches by 16 inches by 16inches cubed, more typically smaller than about 10 inches by 10 inchesby 10 inches cubed, and most typically smaller than about 8 inches by 8inches by 8 inches cubed. One chopper suitable for use may be purchasedfrom Flo-Din. of Moses Lake, Wash. The watermelons are received byand/or otherwise conveyed to one or more receiving tanks 50.

Next, the watermelon pieces are conveyed from a receiving tank 50 to afirst finisher 60. FIGS. 4, 5, 6 and 6A illustrate an embodiment of thefirst finisher 60. As shown in FIG. 4, the first finisher 60 generallyincludes vertical support members 62 and horizontal support members 64.The first finisher 60 further generally includes a receiving chamber 66that receives the watermelon extract, and at least substantiallycylindrical finishing chamber 68 that, along with the drive motorhousing 70, houses the finishing cylinder assembly 72 and drive motor(not shown). The motor is typically an electrical motor or gas engine,or other powered actuator. Preferably, the drive for the motor or engineis a variable drive, more preferably a variable frequency drive.Preferably, the motor or engine engages the central shaft 76 of thefinishing cylinder assembly 72 to drive rotation of the shaft when thefinisher is in operation. One end of the shaft is typically mountedoutside of the cylindrical finishing chamber 68 within the drive motorhousing 70, typically to horizontal support member 78.

The finishing cylinder assembly 72 generally includes a cylindricalfinishing screen 80, which cooperates with the finishing brushes 82 toextract the watermelon extract from the watermelon pieces. The finishingbrushes 82 generally include brush support members 90, a body 92, andbristles 94. Typically, the central shaft 76 is at least substantiallyconcentric, preferably concentric within the cylindrical finishingscreen 80. Typically, the central shaft 76 has a plurality of radiallyextending members 84 spaced at substantially 90 degrees from oneanother, more typically 90 degrees. Preferably, the radially extendingmembers 84 are engaged to central shaft collars 86 by a weld. Thecentral shaft collars 86 engage the central shaft 76. The radiallyextending members 84 are typically threaded at the distal end 88. Thedistal end 88 engages brush support members 90, which themselves engage,typically by utilizing a nut 96 and bolt 98 assembly, to the finishingbrushes 82 that, as discussed above, generally have a body 92 andbristles 94. Spacers and/or nuts between the brush support members 90and the bodies 92 of the finishing brushes 82 operate to help regulatethe amount of watermelon flesh that is removed from the rind. This canalso conceivably be adjusted by adjusting the location of the brushsupport member 90 on the thread end of the radially extending members84.

Each of the bristles 94 of the finishing brushes 82 are typically madeof a synthetic fiber, such as nylon (a polyamide). Preferably, there aretwo sets of four at least substantially evenly spaced brushes, moretypically spaced at 90 degree intervals about the rotating central shaft76. Typically there are four brushes that run the length of thecylindrical finishing screen 80. Typically, the cylindrical finishingscreen 80 has a total diameter of about 8 inches to about 32 inches,more typically from about 12 inches to about 30 inches, and mosttypically a diameter of about 24 inches. The distance from the tipbristles 94 of a finishing brush 82 to the surface of the cylindricalfinishing screen 80 is from about ¾ inch to about 1 inch. Usually, theleading end of the brush 82 is about 1 inch from the cylindricalfinishing screen 80 and the trailing end of the brush 82 is about ¾ inchfrom the cylindrical finishing screen. This allows for the preferredamount of flesh of the watermelon pieces to be removed from the rind.

Typically, watermelon pieces are introduced into the first finisher atone end of the first finisher (also called an “automated separatordevice” herein). As the watermelon pieces rotate inside the firstfinisher, the watermelon flesh attached to the rind substantiallyseparates from the rind. At least a portion of watermelon flesh remainsattached to the watermelon rind. Leaving a portion of watermelon fleshon the watermelon rind prevents rind from being removed. Typically, atleast about 1/16 inch of watermelon flesh remains on the rind. Leavingat least about 1/16 inch of flesh on the rind generally prevents theundesired color and flavor from occurring in the watermelon extract. Theamount of watermelon flesh left on the rind usually ranges from about1/16 inch to about ¼ inch, more typically from about 1/16 inch to about3/16 inch, and most typically about ⅛ inch.

To further prevent removal of too much watermelon flesh, the watermelonpieces should preferably be rotated in the first finisher 60 at a slowspeed. Typically, the radially extending members 84 are operated atabout 180 rpm to about 600 rpm, more typically about 220 rpm to about450 rpm, and most typically about 260 rpm to about 300 rpm. Thecentrifugal force created by the rotating brush assembly 82 pusheswatermelon flesh and juice through the cylindrical finishing screen 80.The mixture of watermelon flesh and juice may also include some seedsdepending on the size of the apertures in the cylindrical finishingscreen. The apertures 93 of the cylindrical finishing screen are about ¼inch in diameter and are equally spaced about ½ inch from one another(measured from the center of each aperture to the center of the nextmost adjacent aperture).

The watermelon extract collects in the receiving chamber 66 of the firstfinisher. Once extracted in the first finisher 60, the extract istypically pumped to a second finisher 100. Typically, one end of thefirst finisher 60 is elevated, so that as the watermelon extract isobtained from the watermelon pieces, gravity helps the waste pieces tofall out the bottom end of the first finisher 60 and into a wastereceiving bin or waste moving auger, which transports the waste away.

The second finisher 100 includes a cylindrical finishing screen with afiner mesh size than the screen in the first finisher 60 and usescentrifugal force to force the extract through the cylindrical screen ofthe second finisher. The second finisher 100 with the finer meshcylindrical screen is used to remove any seeds present in the watermelonextract that may be present after the extract is initially obtained inthe first finisher. While any finisher capable of removing seeds can beused, one finisher suitable for use in the process of the presentinvention is a BROWN™ Finisher, manufactured by Brown InternationalCorp. of Covina Calif.

The watermelon extract is then typically sent to a filter device. Thefilter device 110 substantially separates the watermelon flesh from thewatermelon juice in the extract. The filter device 110 may be anyacceptable filter, such as a SERMIA™ filter, manufactured by SermiaInternational Inc. of Blainville, Quebec, Canada. The SERMIA™ filter isa rotary filter which operates with a gentle centrifugal effect at avariable speed and tilt angle for separation of the solid watermelonflesh in suspension in the watermelon extract. In early testing, thefilter device 110 included a screen with openings of about 80 micron toabout 100 micron, most preferably being an 80 micron screen. Furthertesting indicates that a filter will work that uses a screen of lessthan 80 micron up to a screen of about 0.020″ mesh size (which hasapproximately 510 micron size openings) depending on the desiredthrough-put and quality required of the concentrate being made. Notably,screen sizes of 50 microns or less will remove red color in thewatermelon such that most of the red color has been removed, which isundesirable in many watermelon juice products but which may be desirablein some watermelon juice products. After filtering, the watermelonextract typically includes less than about 2.5% watermelon flesh andmore typically includes less than about 1.5% watermelon flesh.

From the filter device 110, the watermelon juice is typically placed inholding tanks 120 and 130. There, an edible acid is added to thewatermelon juice to adjust the pH of the extract. The acid can be eitheran organic or inorganic acid. Typically, the acid is an organic acid,typically an FDA-approved organic acid, such as citric acid. An organicacid has been found to enhance the microbial stability of the watermelonextract. Before addition of the acid, the pH of the extract in theholding tanks 120 and 130 is about 4.6 to about 7.0. Organic acid isadded to adjust the pH to about 4.2 or less. Typically, the final pH ofthe watermelon juice is about 3.0 to about 4.5, and more typically about3.5 to about 4.2. Typically, from about 1 pound to about 5 pounds oforganic acid per ton of raw fruit is added, more typically from about 2pounds to about 4 pounds of organic acid per ton of raw fruit, and mosttypically about 2.5 pounds organic acid per ton raw fruit is added tothe watermelon juice in holding tanks 120 and 130.

Once the desired pH level is achieved, the watermelon extract is sent tothe evaporator 140. In the evaporator, the watermelon extract is heatedto a minimum temperature of about 170° F. As the water evaporates fromthe extract, the water is removed under a vacuum until a predeterminedBrix level is achieved, usually from about 68 to about 70 Brix such thatwhen the essence, which has no Brix level, is returned, the end Brixlevel of about 65 Brix is obtained. Brix is the measurement by which thepercentage by weight of soluble solids is expressed as the percent ofsucrose in a solution. This measurement at 20° C. can be measured with aBrix hydrometer or with a refractometer calibrated to a Brix scale.

During a preheat stage of the evaporation process, water soluble, clearliquids, referred to as essence, are collected. Essence is the highlyvolatile low-esters which are the main flavor components of thewatermelon juice. The strength of the essence is typically expressed in“fold” terms. For example, “100 fold” means 1 gallon of essence from 100gallons of single strength juice. Typically, available essence isreturned to the watermelon extract during the evaporation process.

After evaporation, the resulting watermelon concentrate is packaged andmay optionally be frozen for storage.

The watermelon concentrate produced by the extraction process of thepresent invention is red in color and possesses a strong watermelonflavor identity, something obviously desired in this fruit-specificproduct. Unlike prior art watermelon concentrate products, thewatermelon extract of the present invention does not possess a fishyodor or flavor. The fishy odor and flavor present in previous watermelonextracts are presently believed to be caused by fatty acids present inthe watermelon rind. These fatty acids are generally the same as thosefound in fish and are what gives fish a “fishy smell.” Althoughadditives, such as colorants, sweeteners (such as sugars and artificialsweeteners such as sucralose) and flavors can be added to mask any fishyodor or smell present, it has been discovered that because of theimproved flavor of the watermelon juice product of the presentinvention, such additives are not necessary.

Substantial separation of the red flesh interior of the watermelon fromthe watermelon rind while leaving a portion of the red flesh interior onthe rind is presently believed to be responsible for the superior redcolor and more true to fruit flavor and smell associated with thewatermelon extract of the present invention.

Using a HUNTER™ colorimeter, the color of the watermelon juice can bemeasured. The measurement of color was done using the HUNTER™ L, A, Bstandard color scale described below. The following test method is usedin this application and examples. HUNTER™ L, A, B values are standardcolor scale values that indicate differences in brightness, hue, andsaturation using a standard color system. The color system utilizes Lvalues to relate lightness and a combination of A and B values to relatehue and croma on a coordinate scale. A-values representredness-greenness and B-values represent yellowness-blueness. L-valuesdescribe the degree of brightness, where a value of 100 equals white andthat of 0 equals black. A-values describe the degree of redness, whichincreases with an increasing A-value. B-values describe the degree ofyellowness, which increases with increasing B-value. Generally, samplesare placed on the sample plane of the colorimeter (which is calibratedusing standard tiles according to the manufacturer's instructions) wherea 45 degree incident light from a quartz-halogen lamp (clear bulb)illuminates the sample. An optical sensor placed at 0 degrees(perpendicular to the sample plane) measures the reflected light. Valuesare reported using a standard HUNTER™ L, A, B color scale. The L valuemeasures the “brightness” of the juice, the A value measures the“redness”, and the B value measures the “brown” in a juice. Using thesevalues, different watermelon juices can be compared and contrasted on aquantitative basis providing real numbers in the comparison. Table 1shows a comparison of the watermelon extract of the present invention ascompared to a prior art watermelon product.

TABLE 1 Prior Art Watermelon Extract Property Cloudy Water- ProducedAccording to Measured melon Juice the Present Invention Brix 61.90 56.6Titratable acidity  1.54 1.59 pH  4.50 4.51 HUNTER ™ color atconcentrate: L value  4.15 22.22 A value 17.11 35.73 B value  7.16 27.37

As shown in Table 1 above, the HUNTER™ color values showing the levelsof brightness and red color in the prior art juice are very poor. An Lvalue of 4.15 indicates a very dull color. An A value of 17.11 indicatesvery little red color associated with the juice. In reality, thisanalytical information points to more of an amber/yellow color typicallyassociated with apple juice than watermelon juice. In contrast, thecolor results of the watermelon juice of the present invention showvastly greater brightness and red values. As can be seen in Table 1, theL value of the juice of the present invention is more than five timesthe L value of the prior art juice, more particularly 18.07 pointshigher. The A value of the juice of the present invention is twice the Lvalue of the prior art, more particularly 18.62 points greater. The Bvalue is 20.21 points higher in the watermelon extract of the presentinvention. Visually, the watermelon juice of the present invention isbright and red, just what one would expect in a quality watermelonjuice. Typically, the watermelon juice of the present inventiontypically has an L value of about 19 to about 24, more typically fromabout 21 to about 23, and most typically about 22. The watermelon juicetypically has an A value of from about 32 to about 37, more typicallyfrom about 34 to about 36, and most typically about 35. The watermelonjuice typically has a B value of about 24 to about 30, more typicallyfrom about 26 to about 28, and most typically about 27.

The watermelon concentrate or other extract of the present inventiontypically contains a TPC of bacteria of less than about 1000/g, moretypically less than about 700/g, and most typically less than about500/g watermelon juice.

Watermelon juice, juice (cloudy or clarified) concentrate, or otherextract can be used in a myriad of food products, including beverages,sorbet, yogurt, sauces, salad dressings, fruit salad desserts, bakeryfillings, candy, and bar mixes.

The process and watermelon juice concentrate as described herein isdirected to a cloudy watermelon juice. However, those skilled in the artwill appreciate that the process of the present invention can also beused to produce clarified watermelon juice.

To prepare clarified juice, the cloudy juice is typically strained usingclean press cloths, a rotating screen, or a vibrating-type shakerscreen. After straining, the juice may be further clarified using one ofthe following methods: enzymatic, bentonite, gelatin-tannin, andelectrokinetic absorption. The enzymatic method involves heating thejuice and then adding pectolytic enzymes, which break down the naturalpectin in the juice. In the bentonite method, the juice is heated toapproximately 190° F., held for a few seconds, and then cooled rapidly.Then, typically a mixture of equal parts of bentonite and filter aid areadded to the juice. The heat treatment coagulates colloidal material inthe juice. The bentonite/filter aid mixture causes the coagulatedcolloidal material to flocculate, which is then filtered. In thegelatin-tannin method, gelatin is dissolved in water and then added tothe cloudy juice. The gelatin combines with the tannins in the juice toform a precipitate. The juice is clarified when the precipitate settlesout and pulls suspended fruit material in the juice down with it. Theelectrokinetic adsorption method uses a cartridge filter. The cartridgefilter provides electrokinetic adsorption and small-pore mechanicalstraining. The filter medium is composed of cellulose and polymerfibers, which impart a positive charge. After the juice is clarified, itis mixed with a filter aid, such as diatomaceous earth or siliceouspowder. It is then filtered through a filter cloth or filter paper. Thefilter aid along with the fruit material separated during theclarification process is caught on the filter cloth or filter paper.

As shown generally in FIG. 8, the process of producing clarifiedwatermelon concentrate 190 of the present invention generally utilizesthe same process as producing cloudy watermelon extract up until thewatermelon extract has passed through the second finisher 100.Thereafter, instead of proceeding to a filter and being processedfurther as generally shown in FIG. 1, the extract is moved to a decanter(hold tank) 200 and the waste product is placed in drums. Next, theliquid extract is centrifuged 210 and the waste returned to the decanterhold tank.

The product from the centrifuge is transported or otherwise moved to afirst holding tank 215 where, as in the process for preparing a cloudyextract, an organic acid, typically citric acid, is added to lower thepH to at least about 4.2 or less, typically to about 4.0. Typically, thesame amount of acid per ton of raw fruit as used in lowering the pH ofcloudy extract is also used to lower the pH at this stage as well. Theextract in holding tank 215 is typically moved to a second holding tank220. About 3 oz. of a pectin enzyme, such as ADEX G enzyme, per 2,000gallons of extract is added. The blend is held for about ½ hour.

Once treated with the pectin enzyme and the pH has been adjusted, theenzyme-treated extract is moved or otherwise transported to feed tank230. The feed tank feeds the extract into a regeneration heat exchanger240. The regeneration heat exchanger heats the extract to about 180° F.,which causes the remaining cloudy portion of the extract to formdiscrete masses or clumps of cloudy material. The extract is then cooledto a temperature of from about 40° F. to about 50° F. The extract withthe discrete masses is then passed through a diatomaceous earth (DE)filter 250, which removes the discrete masses from the extract. Thethermal processing of the extract in the temperature line heaterfacilitates the removal of the cloudy portion of the extract by thediatomaceous earth filter by forming the larger masses of cloudymaterial. Thereafter, the clarified (colorless or at least substantiallycolorless) extract is then typically evaporated and packaged asdiscussed above regarding the production of the cloudy concentrate. Theclarified extract typically has a Brix of about 65, a pH of from about3.8 to about 4.5, an acidity of from about 1.0 to about 3.0% by weightas citric at 65 Brix. The clarity of the clarified extract is typicallyat least about 80% transmittance at 625 nm, 7.8 Brix. The color of theclarified extract is about 35% or less transmittance at 440 nm, 7.8Brix. The total plate count of the clarified extract is typically lessthan about 500/g.

Testing has shown that the present apparatus and process can be used onmelons other than watermelon, such as cantaloupe and other muskmelons,and honeydew melons. In such case, the machinery and process can beadapted/adjusted for the particulars of the melon being processed . . .such as by adjusting or changing the equipment to remove more (or less)flesh from the rind (including changing piece sizes of rind parts),adjusting or changing equipment for different processing speeds and fordifferent levels of filtering to obtain a desired quality of juiceproduct and adjusting the equipment for optimal operating temperaturesand steam pressures for a particular fruit.

For cantaloupe melon, the same process can be used as described above.However, testing has shown that plugging of screens can be a problem andmust be appropriately managed. For example, cantaloupe may be “green” onday 1, acceptably ripe on days 2-3, and overripe or rotten on day 4.“Green” cantaloupe may result in small balls that plug openings in ascreen. “Overripe” cantaloupe may result in rind that is leathery suchthat it tends to generate long strips that plug openings in screens.This can be controlled in part by controlling a quality of melon putinto the equipment, but also can be helped by providing screens withlarger opening sizes, slower through-put, and lower operatingtemperatures. In particular, steaming the cantaloupe to remove bacteriamay also need to be adjusted since cantaloupe tend to be affected bysteam more quickly (due to their smaller size and also due to theirthinner, different rind), such that the steam temperature, force,locations of application, and/or total time of steam treatment may needto be adjusted downward. The present apparatus and process forwatermelon can be modified to deal with these items such as by providinga cutter or disintegrator that reduces the cantaloupe to pieces to asmaller size than watermelon. For cantaloupe, it is preferred that thechopped pieces be a maximum of 4″×6″×½″ in size, or more preferably beabout 1″×1″×¼″ in size. The cantaloupe is moved to the disintegrator byan auger that is shaped and adapted to move the cantaloupe at a slowerpace than watermelon and without unacceptable smashing, so that thepieces (including bits of rind) are not turned into a puree-likesubstance. Generally, a similar amount of flesh (i.e., about 1/16″) canbe left on the cantaloupe rind (as compared to watermelon) whenseparating the flesh from the rind, but it is noted that perhapsslightly more flesh can be removed without compromising taste and juicequality. Notably, cantaloupe juice is not normally concentrated, suchthat the collected juice is placed in storage containers and frozenwithout concentrating steps. The cantaloupe piece is not heated in theevaporator. Applicants have found that the heat of the evaporatorsubstantially eliminates the flavor of the juice.

For honeydew melon, the machinery and process are more similar toprocessing of watermelon. Nonetheless, even here, parameters andequipment potentially need to be adjusted or adapted for particularcharacteristics and properties of the honeydew melon. For example,honeydew melon break apart in a slightly different manner thanwatermelon. Honeydew melon generally break apart with less of an“exploding” action such as is found in watermelon. This is affected byripeness of the melon, rind thickness, size of the fruit, and particularfamily types of honeydew melons, as well as by the faster effect ofsteam cleaning on the honeydew melon.

It is contemplated that other melons with rinds can be processed forextracting juice by the present apparatus and method through fine-tuningand adjusting the equipment and operating parameters, as discussedabove.

In the foregoing description, it will be readily appreciated by thoseskilled in the art that modifications may be made to the inventionwithout departing from the concepts disclosed herein. Such modificationsare to be considered as included in the following claims, unless theseclaims by their language expressly state otherwise.

We claim:
 1. An apparatus comprising: a separator finisher configured toseparate melon flesh from melon rind of melon pieces while leaving adepth of melon flesh on the melon rind, comprising: a cylindricalfinishing screen having a top end elevated above a bottom end whereinthe bottom end is configured to allow melon rind having a depth of melonflesh on the melon rind fall out of the bottom end and wherein thecylindrical finishing screen defines a screen interior volume disposedwithin the separator finisher for receiving melon pieces having melonrind and melon flesh on the melon rind; a shaft disposed within thescreen interior volume of the cylindrical finishing screen and operablycoupled to a motor to rotate the shaft; a plurality of radiallyextending members having a distal end portion operably engaged with theshaft and extending outwardly from the shaft; and a plurality of brushesoperably coupled to the distal end portion of the plurality of radiallyextending members and configured to pass by the melon rind to separatethe melon flesh from the melon rind and push the melon flesh through thecylindrical finishing screen as the melon pieces pass from the top endto the bottom end.
 2. The apparatus defined in claim 1, wherein theseparator finisher further includes a finishing chamber that houses thecylindrical finishing screen and a receiving chamber that receives themelon flesh.
 3. The apparatus defined in claim 2, wherein the pluralityof radially extending members are radially adjustable and wherein theplurality of brushes includes a body and bristles that extend radiallyoutwardly from the body to separate melon flesh from melon rind and thereceiving chamber is positioned below the cylindrical finishing screen.4. The apparatus defined in claim 3, wherein the depth of flesh is atleast about 1/16 inch of melon flesh on the melon rind.
 5. The apparatusdefined in claim 4, wherein the depth of flesh is at least about ⅛ inchof melon flesh on the melon rind.
 6. The apparatus defined in claim 3,wherein the plurality of brushes are adjustable to leave a set depth ofmelon flesh on the melon rind.
 7. The apparatus defined in claim 3,wherein the plurality of brushes are made of a synthetic fiber.
 8. Theapparatus defined in claim 3, wherein the plurality of brushes areelongated and angled relative to the melon rind to pass by the melonrind with decreasing depth as the brushes are moved past the rindpieces.
 9. The apparatus defined in claim 1, wherein the separatorfinisher includes a screen with apertures of less than about ¼ inchdiameter.
 10. The apparatus defined in claim 9, wherein the aperturesare less than about 100 microns in size.
 11. The apparatus defined inclaim 1, including a concentrator for concentrating the melon juice toform a concentrate at least 5 times to 10 times stronger than singlestrength juice.
 12. The apparatus defined in claim 11, further includinga steamer for steaming whole melon prior to the separator in order toreduce bacteria count.
 13. The apparatus defined in claim 12, includinga chopper for chopping the melon into the melon pieces less than 16inches cubed and positioned upstream of the finisher.
 14. An apparatusfor preparing a melon juice product comprising: a separator finisher forseparating melon flesh from melon rind while leaving a depth of melonflesh on the melon rind, comprising: a cylindrical finishing screen thatdefines a screen interior volume disposed within the separator finisherfor receiving melon pieces having melon rind and melon flesh on themelon rind; a shaft disposed within the screen interior volume of thecylindrical finishing screen and operably coupled to a motor to rotatethe shaft; a plurality of radially extending members having a distal endportion operably engaged with the shaft and extending outwardly from theshaft; a plurality of brushes operably coupled to the distal end portionof the plurality of radially extending members and configured to pass bythe melon rind with decreasing depth to separate the melon fleshtherefrom; and a receiving chamber positioned below the cylindricalfinishing screen that receives the melon flesh that is separated fromthe melon rind.
 15. The apparatus defined in claim 14, wherein theplurality of brushes are configured to leave the depth of melon flesh onthe melon rind and wherein the depth of the melon flesh on the melonrind is at least about 1/16 inch of melon flesh on the melon rind. 16.The apparatus defined in claim 15, wherein the plurality of brushes areconfigured to leave the depth of melon flesh on the melon rind andwherein the depth of the melon flesh on the melon rind is at least about⅛ inch of melon flesh on the melon rind.
 17. The apparatus defined inclaim 14, wherein the plurality of brushes are adjustable to leave thedepth of melon flesh on the melon rind.
 18. The apparatus defined inclaim 14, wherein the plurality of brushes are made of a synthetic fiberand wherein the plurality of radially extending members are radiallyadjustable.
 19. The apparatus defined in claim 14, wherein the pluralityof brushes are elongated and angled relative to the melon rind to passby the melon rind with decreasing depth as the brushes are moved pastthe rind pieces.
 20. The apparatus defined in claim 14, wherein theseparator includes a screen with apertures of less than about ¼ inchdiameter and wherein the distal end portion on the plurality of radiallyextending members are threaded.
 21. The apparatus defined in claim 20,wherein the screen apertures are less than about 100 microns in size.